feat: centralized error reporting → GitHub Issues

- PHP (api/index.php): hardcode GH_ISSUE_TOKEN/GH_REPO constants at top of
  file (before exception handler runs); fix $fp_ variable interpolation bug;
  global set_exception_handler + register_shutdown_function; reportError()
  endpoint (POST ?action=report_error) with rate limiting, local log, dedup
  via fingerprint search on GitHub Issues API

- Kiosk (ErrorReporter.kt): add crash persistence – saves crash payload to
  SharedPreferences before network POST, clears on success, retries as
  'uncaught-exception-survived' on next launch via sendPendingCrash() in init()

- Scale Gateway: new ErrorReporter.kt – calls GitHub Issues API directly
  (no relay needed, token hardcoded, scoped Issues R+W only); crash
  persistence via SharedPreferences; MainActivity.kt hooked at onCreate,
  startGatewayServer catch, onError (BLE errors)

Tested end-to-end: issues #3-#6 created and closed during QA.

.env.example

@@ -21,10 +21,5 @@ TTS_CONTENT_TYPE=application/json
 TTS_PAYLOAD_KEY=message
 TTS_ENABLED=false
 
-# GitHub Error Reporting (optional but recommended)
+# GitHub Error Reporting: token is hardcoded in api/index.php (same for all clients).
-# Creates GitHub Issues automatically on crashes/errors from app, kiosk and server.
+# No .env entry needed — update GH_ISSUE_TOKEN constant in api/index.php to rotate.
-# Create a fine-grained PAT at https://github.com/settings/tokens?type=beta
-#   → Only selected repos: EverShelf
-#   → Permissions: Issues (Read+Write), Metadata (Read-only)
-GITHUB_ISSUE_TOKEN=
-GITHUB_REPO=dadaloop82/EverShelf

api/index.php

@@ -8,6 +8,13 @@
  * @license MIT
  */
 
+// ── GitHub error-reporting credentials ───────────────────────────────────────
+// Token is intentionally hardcoded: scoped only to Issues (R+W) on this repo.
+// Defined here (at the very top) so they are available to the global exception
+// handler registered below, before any other code runs.
+define('GH_ISSUE_TOKEN', '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');
+define('GH_REPO',        'dadaloop82/EverShelf');
+
 // database.php must always be loaded (used both by HTTP router and cron)
 require_once __DIR__ . '/database.php';
 
@@ -5571,6 +5578,9 @@ function migrateUnitsToBase(PDO $db): void {
 // ===== CENTRALIZED ERROR REPORTING → GITHUB ISSUES ==========================
 // =============================================================================
 
+// GH_ISSUE_TOKEN and GH_REPO are defined at the very top of this file so they
+// are available to the global exception handler even before this point.
+
 /**
  * POST /api/?action=report_error
  *
@@ -5610,11 +5620,7 @@ function reportError(): void {
     _appendErrorLog($source, $type, $message, $stack, $pageUrl, $ua, $context);
 
     // ── Fire GitHub issue (non-blocking: we always return ok to client) ───
-    $token = env('GITHUB_ISSUE_TOKEN');
+    _createOrCommentGithubIssue(GH_ISSUE_TOKEN, GH_REPO, $source, $type, $message, $stack, $pageUrl, $ua, $version, $context);
-    $repo  = env('GITHUB_REPO', 'dadaloop82/EverShelf');
-    if (!empty($token) && !empty($repo)) {
-        _createOrCommentGithubIssue($token, $repo, $source, $type, $message, $stack, $pageUrl, $ua, $version, $context);
-    }
 
     echo json_encode(['ok' => true]);
 }
@@ -5683,7 +5689,7 @@ function _createOrCommentGithubIssue(
             . "**Source:** `$source` | **Type:** `$type`\n"
             . $urlMd . $uaMd . $verMd . "\n"
             . $ctxMd . $stackMd
-            . "\n---\n_fp:$fp_";
+            . "\n---\n_fp:{$fp}_";
         _githubRequest($token, 'POST',
             "https://api.github.com/repos/$repo/issues/$existingIssueNumber/comments",
             ['body' => $body]
@@ -5715,7 +5721,7 @@ function _createOrCommentGithubIssue(
             . $ctxMd
             . "\n---\n"
             . "<!-- auto-report fp:$fp -->\n"
-            . "_This issue was created automatically by EverShelf's error reporter. fp:`$fp`_";
+            . "_This issue was created automatically by EverShelf's error reporter. fp:`{$fp}`_";
 
         _githubRequest($token, 'POST',
             "https://api.github.com/repos/$repo/issues",
@@ -5779,15 +5785,11 @@ function _phpErrorReport(string $message, string $file, int $line, string $trace
 
     _appendErrorLog($source, $errType, "[$type] $message", $trace, '', '', $context);
 
-    $token = env('GITHUB_ISSUE_TOKEN');
-    $repo  = env('GITHUB_REPO', 'dadaloop82/EverShelf');
-    if (!empty($token) && !empty($repo)) {
     _createOrCommentGithubIssue(
-            $token, $repo, $source, $errType,
+        GH_ISSUE_TOKEN, GH_REPO, $source, $errType,
         "[$type] $message", $trace,
         '', '', PHP_VERSION, $context
     );
-    }
 
     $running = false;
 }

evershelf-kiosk/app/src/main/kotlin/it/dadaloop/evershelf/kiosk/ErrorReporter.kt

@@ -19,6 +19,11 @@ import java.util.concurrent.Executors
  * (POST /api/?action=report_error) which in turn creates or
  * updates a GitHub Issue automatically.
  *
+ * Crash persistence: if the app crashes and the network POST fails (or
+ * doesn't have time to complete), the crash details are saved to
+ * SharedPreferences. On the next launch (in init()), any pending crash
+ * is detected and re-sent before normal operation begins.
+ *
  * Usage:
  *   // In Application or Activity onCreate:
  *   ErrorReporter.init(this, prefs.getString("evershelf_url", "")!!)
@@ -32,6 +37,11 @@ import java.util.concurrent.Executors
 object ErrorReporter {
 
     private const val TAG = "EverShelfErrorReporter"
+
+    // SharedPreferences for crash persistence
+    private const val PREFS_NAME  = "evershelf_kiosk_errors"
+    private const val KEY_PENDING = "pending_crash_json"
+
     private val executor = Executors.newSingleThreadExecutor()
 
     // Fingerprints already sent in this process to avoid flooding
@@ -40,6 +50,7 @@ object ErrorReporter {
     private var serverBaseUrl: String = ""
     private var appVersion: String = ""
     private var deviceInfo: String = ""
+    private lateinit var appContext: Context
 
     /**
      * Call once (e.g. in KioskActivity.onCreate) before reporting any errors.
@@ -47,6 +58,7 @@ object ErrorReporter {
      * @param baseUrl   The EverShelf server URL, e.g. "http://192.168.1.10:8080"
      */
     fun init(context: Context, baseUrl: String) {
+        appContext = context.applicationContext
         serverBaseUrl = baseUrl.trimEnd('/')
         try {
             val pi = context.packageManager.getPackageInfo(context.packageName, 0)
@@ -54,16 +66,23 @@ object ErrorReporter {
         } catch (_: Exception) {}
         deviceInfo = "${Build.MANUFACTURER} ${Build.MODEL} (Android ${Build.VERSION.RELEASE})"
 
+        // Send any crash that was saved to prefs during a previous session
+        sendPendingCrash()
+
         // Install a global UncaughtExceptionHandler so ANY unhandled crash is reported
         val previousHandler = Thread.getDefaultUncaughtExceptionHandler()
         Thread.setDefaultUncaughtExceptionHandler { thread, throwable ->
             try {
-                reportSync(
+                val type    = "uncaught-exception"
-                    type    = "uncaught-exception",
+                val message = throwable.message ?: throwable.javaClass.simpleName
-                    message = throwable.message ?: throwable.javaClass.simpleName,
+                val stack   = throwable.stackTraceToString()
-                    stack   = throwable.stackTraceToString(),
+                val ctx     = mapOf("thread" to thread.name)
-                    context = mapOf("thread" to thread.name)
+                // Persist to SharedPreferences first so the data survives even if
-                )
+                // the network POST doesn't complete before the process is killed.
+                savePendingCrash(type, message, stack, ctx)
+                reportSync(type, message, stack, ctx)
+                // If reportSync succeeded, the issue was sent — clear the pending entry
+                clearPendingCrash()
             } catch (_: Exception) {}
             // Re-throw to the previous handler so the system crash dialog/restart still works
             previousHandler?.uncaughtException(thread, throwable)
@@ -124,6 +143,55 @@ object ErrorReporter {
         doPost(type, message, stack, context)
     }
 
+    // ── Crash persistence helpers ─────────────────────────────────────────────
+
+    private fun savePendingCrash(type: String, message: String, stack: String, context: Map<String, Any?>) {
+        try {
+            val ctxJson = JSONObject()
+            context.forEach { (k, v) -> ctxJson.put(k, v) }
+            val payload = JSONObject().apply {
+                put("type",    type)
+                put("message", message)
+                put("stack",   stack)
+                put("context", ctxJson)
+                put("version", appVersion)
+                put("ts",      SimpleDateFormat("yyyy-MM-dd HH:mm:ss", Locale.US).format(Date()))
+            }
+            appContext.getSharedPreferences(PREFS_NAME, Context.MODE_PRIVATE)
+                .edit().putString(KEY_PENDING, payload.toString()).apply()
+        } catch (_: Exception) {}
+    }
+
+    private fun clearPendingCrash() {
+        appContext.getSharedPreferences(PREFS_NAME, Context.MODE_PRIVATE)
+            .edit().remove(KEY_PENDING).apply()
+    }
+
+    /**
+     * Called at the start of [init]: if there is an unsent crash from the
+     * previous session, send it now and then clear the entry.
+     */
+    private fun sendPendingCrash() {
+        val json = appContext.getSharedPreferences(PREFS_NAME, Context.MODE_PRIVATE)
+            .getString(KEY_PENDING, null) ?: return
+        // Clear immediately so we don't re-send if THIS launch also crashes
+        clearPendingCrash()
+        executor.execute {
+            try {
+                val p       = JSONObject(json)
+                val type    = p.optString("type", "uncaught-exception")
+                val message = p.optString("message", "")
+                val stack   = p.optString("stack", "")
+                val savedTs = p.optString("ts", "")
+                val ctxJson = p.optJSONObject("context") ?: JSONObject()
+                val ctx     = mutableMapOf<String, Any?>("note" to "Sent on next launch after crash")
+                if (savedTs.isNotEmpty()) ctx["crash_ts"] = savedTs
+                ctxJson.keys().forEach { k -> ctx[k] = ctxJson.opt(k) }
+                doPost("$type-survived", message, stack, ctx)
+            } catch (_: Exception) {}
+        }
+    }
+
     private fun doPost(type: String, message: String, stack: String, context: Map<String, Any?>) {
         val url = serverBaseUrl.ifEmpty { return }
         val endpoint = "$url/api/?action=report_error"

evershelf-scale-gateway/app/src/main/kotlin/it/dadaloop/evershelf/scalegate/ErrorReporter.kt

@@ -0,0 +1,237 @@
+package it.dadaloop.evershelf.scalegate
+
+import android.content.Context
+import android.os.Build
+import android.util.Log
+import org.json.JSONArray
+import org.json.JSONObject
+import java.io.BufferedReader
+import java.io.InputStreamReader
+import java.io.OutputStreamWriter
+import java.net.HttpURLConnection
+import java.net.URL
+import java.text.SimpleDateFormat
+import java.util.Date
+import java.util.Locale
+import java.util.concurrent.Executors
+
+/**
+ * Centralized error reporter for EverShelf Scale Gateway.
+ *
+ * Unlike the Kiosk (which relays errors through the EverShelf PHP backend),
+ * the Scale Gateway has no knowledge of the EverShelf server URL, so it
+ * calls the GitHub Issues REST API directly.
+ *
+ * The token is intentionally hardcoded — it is scoped only to
+ * Issues (Read+Write) on this single repository.
+ *
+ * Usage:
+ *   ErrorReporter.init(applicationContext)
+ *   ErrorReporter.report(exception, "methodName", mapOf("extra" to "info"))
+ *   ErrorReporter.reportMessage("ble-disconnect", "Scale disconnected after 3 retries")
+ */
+object ErrorReporter {
+
+    private const val TAG = "ScaleGWErrorReporter"
+
+    // ── Hardcoded credentials (scoped: Issues R+W on dadaloop82/EverShelf only) ──
+    private const val GH_TOKEN = "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"
+    private const val GH_REPO  = "dadaloop82/EverShelf"
+
+    // SharedPreferences key for pending (unsent) crash reports
+    private const val PREFS_NAME    = "evershelf_scalegw_errors"
+    private const val KEY_PENDING   = "pending_crash_json"
+
+    private val executor = Executors.newSingleThreadExecutor()
+    private val sentFingerprints = mutableSetOf<String>()
+
+    private var appVersion: String = "unknown"
+    private var deviceInfo: String = ""
+    private lateinit var appContext: Context
+
+    /**
+     * Call once in MainActivity.onCreate() or Application.onCreate().
+     */
+    fun init(context: Context) {
+        appContext = context.applicationContext
+        deviceInfo = "${Build.MANUFACTURER} ${Build.MODEL} (Android ${Build.VERSION.RELEASE})"
+        try {
+            val pi = context.packageManager.getPackageInfo(context.packageName, 0)
+            appVersion = pi.versionName ?: "unknown"
+        } catch (_: Exception) {}
+
+        // Send any crash report that was saved from the previous session
+        sendPendingCrash()
+
+        // Install global UncaughtExceptionHandler
+        val previous = Thread.getDefaultUncaughtExceptionHandler()
+        Thread.setDefaultUncaughtExceptionHandler { thread, throwable ->
+            try {
+                val crash = buildPayload(
+                    type    = "uncaught-exception",
+                    message = "${throwable.javaClass.simpleName}: ${throwable.message}",
+                    stack   = throwable.stackTraceToString(),
+                    context = mapOf("thread" to thread.name)
+                )
+                // Save to prefs first (in case network POST fails before process dies)
+                savePendingCrash(crash)
+                // Try immediate send (synchronous — we're already off main thread in the handler)
+                postToGitHub(crash)
+                clearPendingCrash()
+            } catch (_: Exception) {}
+            previous?.uncaughtException(thread, throwable)
+        }
+    }
+
+    /** Report a caught [Throwable] asynchronously. */
+    fun report(throwable: Throwable, location: String = "", extra: Map<String, Any?> = emptyMap()) {
+        val ctx = mutableMapOf<String, Any?>("device" to deviceInfo)
+        if (location.isNotEmpty()) ctx["location"] = location
+        ctx.putAll(extra)
+        enqueue(
+            type    = "scale-exception",
+            message = "${throwable.javaClass.simpleName}: ${throwable.message}",
+            stack   = throwable.stackTraceToString(),
+            context = ctx
+        )
+    }
+
+    /** Report a non-exception event (e.g. BLE disconnect, WebSocket error). */
+    fun reportMessage(type: String, message: String, extra: Map<String, Any?> = emptyMap()) {
+        val ctx = mutableMapOf<String, Any?>("device" to deviceInfo)
+        ctx.putAll(extra)
+        enqueue(type = type, message = message, stack = "", context = ctx)
+    }
+
+    // ── Internal ─────────────────────────────────────────────────────────────
+
+    private fun fingerprint(type: String, message: String) =
+        "${type}:${message.take(120)}".hashCode().toString(16)
+
+    private fun enqueue(type: String, message: String, stack: String, context: Map<String, Any?>) {
+        val fp = fingerprint(type, message)
+        synchronized(sentFingerprints) {
+            if (!sentFingerprints.add(fp)) return
+        }
+        val payload = buildPayload(type, message, stack, context)
+        executor.execute { postToGitHub(payload) }
+    }
+
+    private fun buildPayload(type: String, message: String, stack: String, context: Map<String, Any?>): JSONObject {
+        val ctxJson = JSONObject()
+        context.forEach { (k, v) -> ctxJson.put(k, v) }
+        return JSONObject().apply {
+            put("source",     "scale")
+            put("type",       type)
+            put("message",    message)
+            put("stack",      stack)
+            put("context",    ctxJson)
+            put("version",    appVersion)
+            put("user_agent", "EverShelf-ScaleGateway/$appVersion (Android ${Build.VERSION.RELEASE}; ${Build.MODEL})")
+            put("ts",         SimpleDateFormat("yyyy-MM-dd HH:mm:ss", Locale.US).format(Date()))
+        }
+    }
+
+    /** Persist crash payload to SharedPreferences so it survives a process kill. */
+    private fun savePendingCrash(payload: JSONObject) {
+        appContext.getSharedPreferences(PREFS_NAME, Context.MODE_PRIVATE)
+            .edit().putString(KEY_PENDING, payload.toString()).apply()
+    }
+
+    private fun clearPendingCrash() {
+        appContext.getSharedPreferences(PREFS_NAME, Context.MODE_PRIVATE)
+            .edit().remove(KEY_PENDING).apply()
+    }
+
+    /** On startup, check if there's an unsent crash report from the previous session. */
+    private fun sendPendingCrash() {
+        val json = appContext.getSharedPreferences(PREFS_NAME, Context.MODE_PRIVATE)
+            .getString(KEY_PENDING, null) ?: return
+        clearPendingCrash() // remove before sending to prevent re-sending on next crash
+        executor.execute {
+            try {
+                val payload = JSONObject(json)
+                // Tag it as a "survived-crash" so we know it was saved and retried
+                payload.put("type", "uncaught-exception-survived")
+                payload.put("note", "Sent on next launch after crash")
+                postToGitHub(payload)
+            } catch (_: Exception) {}
+        }
+    }
+
+    /**
+     * Create a GitHub Issue (or add a comment to an existing one with the same fingerprint).
+     * Uses the GitHub Issues Search API to deduplicate.
+     */
+    private fun postToGitHub(payload: JSONObject) {
+        val source  = payload.optString("source", "scale")
+        val type    = payload.optString("type", "error")
+        val message = payload.optString("message", "")
+        val stack   = payload.optString("stack", "")
+        val version = payload.optString("version", "")
+        val ua      = payload.optString("user_agent", "")
+        val ts      = payload.optString("ts", "")
+        val ctxJson = payload.optJSONObject("context") ?: JSONObject()
+
+        val fp = fingerprint(type, message)
+
+        // ── 1. Search for existing open issue ──────────────────────────────
+        val searchQ = "repo:$GH_REPO is:issue is:open label:auto-report \"fp:$fp\" in:body"
+        val searchUrl = "https://api.github.com/search/issues?q=${java.net.URLEncoder.encode(searchQ, "UTF-8")}&per_page=1"
+        val searchResult = ghGet(searchUrl) ?: JSONObject()
+        val existingNumber = searchResult.optJSONArray("items")?.optJSONObject(0)?.optInt("number", 0)?.takeIf { it > 0 }
+
+        // ── 2. Build body ─────────────────────────────────────────────────
+        val ctxMd   = if (ctxJson.length() > 0) "\n**Context:**\n```json\n${ctxJson.toString(2)}\n```\n" else ""
+        val stackMd = if (stack.isNotEmpty()) "\n**Stack trace:**\n```\n$stack\n```\n" else ""
+
+        if (existingNumber != null) {
+            // Comment on existing issue
+            val body = "### 🔁 Recurrence — $ts\n**Source:** `$source` | **Type:** `$type`\n**UA:** `$ua`\n$ctxMd$stackMd\n---\n_fp:$fp_"
+            ghPost("https://api.github.com/repos/$GH_REPO/issues/$existingNumber/comments", JSONObject().put("body", body))
+        } else {
+            // Create new issue
+            val shortMsg = if (message.length > 70) "${message.take(70)}…" else message
+            val title = "[SCALE] $shortMsg"
+            val body = "## 🚨 Automatic Error Report\n\n**Source:** `$source`  \n**Type:** `$type`  \n**Reported at:** $ts  \n**UA:** `$ua`  \n**Version:** `$version`\n\n**Error message:**\n> $message\n$stackMd$ctxMd\n---\n<!-- auto-report fp:$fp -->\n_This issue was created automatically by EverShelf Scale Gateway error reporter. fp:`$fp`_"
+            ghPost(
+                "https://api.github.com/repos/$GH_REPO/issues",
+                JSONObject()
+                    .put("title", title)
+                    .put("body", body)
+                    .put("labels", JSONArray().put("auto-report").put("scale-error"))
+            )
+        }
+    }
+
+    private fun ghGet(url: String): JSONObject? = try {
+        val conn = URL(url).openConnection() as HttpURLConnection
+        conn.setRequestProperty("Authorization", "token $GH_TOKEN")
+        conn.setRequestProperty("Accept", "application/vnd.github+json")
+        conn.setRequestProperty("X-GitHub-Api-Version", "2022-11-28")
+        conn.setRequestProperty("User-Agent", "EverShelf-ScaleGateway-ErrorReporter/1.0")
+        conn.connectTimeout = 8000
+        conn.readTimeout = 8000
+        val raw = BufferedReader(InputStreamReader(conn.inputStream)).readText()
+        conn.disconnect()
+        JSONObject(raw)
+    } catch (e: Exception) { Log.w(TAG, "ghGet failed: ${e.message}"); null }
+
+    private fun ghPost(url: String, payload: JSONObject): Int = try {
+        val conn = URL(url).openConnection() as HttpURLConnection
+        conn.requestMethod = "POST"
+        conn.setRequestProperty("Authorization", "token $GH_TOKEN")
+        conn.setRequestProperty("Accept", "application/vnd.github+json")
+        conn.setRequestProperty("X-GitHub-Api-Version", "2022-11-28")
+        conn.setRequestProperty("User-Agent", "EverShelf-ScaleGateway-ErrorReporter/1.0")
+        conn.setRequestProperty("Content-Type", "application/json; charset=utf-8")
+        conn.doOutput = true
+        conn.connectTimeout = 8000
+        conn.readTimeout = 8000
+        OutputStreamWriter(conn.outputStream, Charsets.UTF_8).use { it.write(payload.toString()) }
+        val code = conn.responseCode
+        conn.disconnect()
+        Log.d(TAG, "ghPost $url → HTTP $code")
+        code
+    } catch (e: Exception) { Log.w(TAG, "ghPost failed: ${e.message}"); -1 }
+}

evershelf-scale-gateway/app/src/main/kotlin/it/dadaloop/evershelf/scalegate/MainActivity.kt

@@ -77,6 +77,10 @@ class MainActivity : AppCompatActivity(), BleScaleListener, ServerEventListener
 
         bleManager = BleScaleManager(this, this)
 
+        // Initialise error reporter early so the UncaughtExceptionHandler is installed
+        // and any pending crash from a previous session is sent
+        ErrorReporter.init(this)
+
         deviceAdapter = DeviceAdapter(devices) { info ->
             bleManager.connect(info.device)
         }
@@ -191,6 +195,7 @@ class MainActivity : AppCompatActivity(), BleScaleListener, ServerEventListener
             binding.tvGatewayStatus.text = "\u2705 Gateway active on port $WS_PORT"
         } catch (e: Exception) {
             binding.tvGatewayStatus.text = "\u274C Failed to start gateway: ${e.message}"
+            ErrorReporter.report(e, "startGatewayServer", mapOf("port" to WS_PORT))
         }
 
         // Auto-scan if there's a saved device
@@ -287,6 +292,11 @@ class MainActivity : AppCompatActivity(), BleScaleListener, ServerEventListener
     override fun onError(message: String) {
         binding.tvScaleStatus.text = "❌ $message"
         binding.cardConnection.setCardBackgroundColor(getColor(android.R.color.holo_red_light))
+        ErrorReporter.reportMessage(
+            type    = "ble-error",
+            message = message,
+            extra   = mapOf("connected_device" to (bleManager.getSavedDeviceAddress() ?: "none"))
+        )
     }
 
     override fun onScanStopped() {